Brake Master Cylinder Replacement - With Power Brake Booster and Electronic Brake Control Module

Brake Master Cylinder Replacement - With Power Brake Booster and Electronic Brake Control Module

Warning

Brake Fluid Irritant Warning

Warning

The battery must be disconnected to prevent the brake master cylinder from pressurizing the hydraulic system during its automated self diagnostic tests that can possibly occur when a door is opened or the key transmitter is activated. Failure to follow this precaution may cause personal injury.

Caution

If the brake master cylinder has been physically dropped, immediately discard the unit and replace with a new brake master cylinder regardless if any physical damage is visible. A damaged brake master cylinder could cause the braking system to not operate properly.

Caution

Brake Fluid Effects on Paint and Electrical Components Caution Removal Procedure

1. Prepare the brake system control module for removal. Control Module References
2. Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection
3. Thoroughly clean the brake master cylinder reservoir and the brake master cylinder body to remove any dirt and debris.

Brake Master Cylinder Replacement - With Power Brake Booster and Electronic Brake Control Module — figure 1

4. Instrument Panel Lower Insulator Retainer (1) » Remove [2x]

Brake Master Cylinder Replacement - With Power Brake Booster and Electronic Brake Control Module — figure 2

5. Instrument Panel Lower Trim Panel Insulator (1) » Remove

Brake Master Cylinder Replacement - With Power Brake Booster and Electronic Brake Control Module — figure 3

6. Brake Pedal Push Rod Bolt (1) » Remove

Brake Master Cylinder Replacement - With Power Brake Booster and Electronic Brake Control Module — figure 4

7. Brake Pedal Nut (1) » Remove [4x]
8. Raise and support the vehicle. Lifting and Jacking the Vehicle
9. Remove the left front tire and wheel assembly. Tire and Wheel Removal and Installation
10. Front Wheelhouse Liner - Left Side » Remove Front Wheelhouse Liner Replacement

Brake Master Cylinder Replacement - With Power Brake Booster and Electronic Brake Control Module — figure 5

11. Radiator Surge Tank Bolt (1) » Remove

Brake Master Cylinder Replacement - With Power Brake Booster and Electronic Brake Control Module — figure 6

12. Without disconnecting the hoses, remove the radiator surge tank and position aside. (1)

Brake Master Cylinder Replacement - With Power Brake Booster and Electronic Brake Control Module — figure 7

13. Electrical Connector (1) @ Brake Fluid Level Indicator Switch » Disconnect
14. Place a drain pan under the vehicle.

Brake Master Cylinder Replacement - With Power Brake Booster and Electronic Brake Control Module — figure 8

15. Brake Master Cylinder Bolt (1) » Remove [2x]

Brake Master Cylinder Replacement - With Power Brake Booster and Electronic Brake Control Module — figure 9

16. Brake Master Cylinder Reservoir (1) » Remove

Brake Master Cylinder Replacement - With Power Brake Booster and Electronic Brake Control Module — figure 10

17. Brake Master Cylinder Reservoir Seal (1) » Remove and DISCARD [3x]

Brake Master Cylinder Replacement - With Power Brake Booster and Electronic Brake Control Module — figure 11

18. Electrical Connector (1) @ Brake System Control Module » Disconnect

Brake Master Cylinder Replacement - With Power Brake Booster and Electronic Brake Control Module — figure 12

19. Label the brake pipes to ensure they are re-installed in the correct ports of the brake master cylinder.
20. Front and Rear Brake Pipe Nut (1) » Remove [4x]
21. Front and Rear Brake Pipe (2) @ Brake Master Cylinder » Remove
22. Cap the front and rear brake pipe inlets to avoid fluid loss and contamination.

Brake Master Cylinder Replacement - With Power Brake Booster and Electronic Brake Control Module — figure 13

23. Brake Master Cylinder Adapter Nut (1) » Remove

Brake Master Cylinder Replacement - With Power Brake Booster and Electronic Brake Control Module — figure 14

Note

Avoid lifting the brake master cylinder by the electronic brake booster control module or by the brake pedal pushrod.

24. Maneuver the brake master cylinder (1) out of the vehicle through the wheel well.

Brake Master Cylinder Replacement - With Power Brake Booster and Electronic Brake Control Module — figure 15

25. Brake Master Cylinder Gasket (1) » Remove

26. Clean any brake fluid from the underbody area and remove the drain pan from under the vehicle. Installation Procedure

27. Brake Master Cylinder Gasket (1) » Install

Note

Avoid lifting the brake master cylinder by the electronic brake booster control module or by the brake pedal pushrod.

2. Brake Master Cylinder (1) » Install

Caution

Refer to Fastener Caution.

3. Brake Master Cylinder Adapter Nut (1) » Install and tighten — Fastener Specifications

4. Remove the caps from the front and rear brake pipe inlets.

5. Reinstall the front and rear brake pipes (2) as they were labeled during removal.

6. Front and Rear Brake Pipe Nut (1) » Install and tighten [4x] — Fastener Specifications

7. Electrical Connector @ Brake System Control Module (1) » Connect

8. Lubricate the brake master cylinder reservoir seals (1) with GM approved brake fluid from a clean, sealed brake fluid container. Adhesives, Fluids, Lubricants, and Sealers

9. Brake Master Cylinder Reservoir Seal (1) » Install NEW [3x]

10. Brake Master Cylinder Reservoir (1) » Install

11. Brake Master Cylinder Bolt (1) » Install and tighten [2x] — Fastener Specifications

12. Electrical Connector (1) @ Brake Fluid Level Indicator Switch » Connect

13. Radiator Surge Tank (1) » Install

14. Radiator Surge Tank Bolt (1) » Install and tighten — Fastener Specifications

15. Front Wheelhouse Liner - Left Side » Install Front Wheelhouse Liner Replacement

16. Install the left front tire and wheel assembly. Tire and Wheel Removal and Installation

17. Brake Pedal Nut (1) » Install and tighten [4x] — Fastener Specifications

18. If a NEW threaded component is being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded component is reused, prepare the threaded component using the following steps: 18.1. Remove any loose cured adhesive from the external threads of the component using a lint free cloth. 18.2. Thread the cleaned component into the internal mating threads and remove to loosen trapped cured adhesive. 18.3. Apply thread locking adhesive to the external threads of the component. Adhesives, Fluids, Lubricants, and Sealers 18.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

19. Brake Pedal Push Rod Bolt (1) » Install and tighten — Fastener Specifications

20. Instrument Panel Lower Trim Panel Insulator (1) » Install

21. Instrument Panel Lower Insulator Retainer (1) » Install [2x]

22. Connect the battery negative cable. Battery Negative Cable Disconnection and Connection

23. Reprogram the brake system control module. Control Module References

24. Bleed the brake system. Hydraulic Brake System Bleeding

25. Fill the brake master cylinder reservoir to the maximum-full level with GM approved brake fluid from a clean, sealed brake fluid container. Brake Master Cylinder Reservoir Filling

26. Check for brake system leaks.